Concrete block or the like with multiple brick facing and method of making the same

ABSTRACT

A method and resulting structural building unit wherein a conventional masonry cement block, for example, has a portion removed, if necessary, to give it a predetermined vertical height. The presized block is placed upon a continuously moving conveyer and one side of the block is preheated and then coated with a liquid material comprising a polyester resin, a styrene monomer, a solvent, and a catalyst. The stored heat in the block quickly evaporates the solvent and polymerizes the resin and monomer so that a strongly adhering bonding coat is formed on the block. A layer of matrix material of relatively thick consistency, comprising a polyester resin, a styrene monomer, finely divided silica, coloidal silica, and a catalyst is applied to the coated block. The layer of matrix may be one-eighth inch thick or thicker, depending upon the type of building unit that is being made. A facing of brick or other material is partially embedded in the matrix, in spaced relation, to form a facing for the block with simulated mortar joints. The non-embedded portions of the facing are exposed to the atmosphere. Sand is sprinkled on the facing material and the exposed matrix. The matrix is then cured or polymerized by passing the block through a curing oven. The matrix permanently bonds the facing material to the block, and renders the covered side of the block impervious to moisture. The sand adheres to the matrix, but is readily removable from the facing materials.

United States Patent Nichols, Jr. et al.

3,660,214 May 2, 1972 [54] CONCRETE BLOCK OR THE LIKE WITH MULTIPLE BRICK FACING AND METHOD OF MAKING THE SAME [72] Inventors: Charles E. Nichols, Jr., North Augusta,

S.C.; Gerald T. Howard, Gracewood, Ga. [73] Assignee: ,Merry Companles Incorporated, Augusta,

Ga. 22 Filed: Apr.2l, 1969 [21] Appl. No.: 817,980

[521 11.5. CI. ..161/38, 52/309, 52/314, 52/315, 156/298, 161/41, 161/162, 161/206, 161/208 [51] Int. Cl. ..E04c 1104, 844i 7/00, 1332b 5116 [58] Field olSearch ..161/5, 39-41, 139, 161/162, 206, 208, 38; 52/309, 314, 315, 503; 156/298 [56] References Cited UNITED STATES PATENTS 2,850,890 9/ 1958 Rubenstein ..52/309 X 2,951,001 8/1960 Rubenstein..... ....52/309 X 2,219,735 11/1965 lverson et al ..161/5 x 3,232,017 2/1966 Prusinski et al ..52/315 X 3,435,577 4/1969 OLeary ..52/309 3,502,539 3/1970 MacPhail ..161/160 2,718,829 9/1955 Seymour et al. 161/160 X 3,131,514 5/1964 Sick ..52/315 Primary Examiner-Robert F. Burnett Assistant Examiner-Joseph C. Gil Attorney-Bacon & Thomas [5 7] ABSTRACT A method and resulting structural building unit wherein a conventional masonry cement block, for example, has a portion removed, if necessary, to give it a predetermined vertical height. The presized block is placed upon a continuously moving conveyer and one side of the block is preheated and then coated with a liquid material comprising a polyester resin, a styrene monomer, a solvent, and a catalyst. The stored heat in the block quickly evaporates the solvent and polymerizes the resin and monomer so that a strongly adhering bonding coat is formed on the block. A layer of matrix material of relatively thick consistency, comprising a polyester resin, a styrene monomer, finely divided silica, ooloidal silica, and a catalyst is applied to the coated block. The layer of matrix may be oneeighth inch thick or thicker, depending upon the type of building unit that is being made. A facing of brick or other material is partially embedded in the matrix, in spaced relation, to form a facing for the block with simulated mortar joints. The nonembedded portions of the facing are exposed to the atmosphere. Sand is sprinkled on the facing material and the exposed matrix. The matrix is then cured or polymerized by passing the block through a curing oven. The matrix permanently bonds the facing material to the block, and renders the covered side of the block impervious to moisture. The

sand adheres to the matrix, but is readily removable from the facing materials.

29 Claims, 19 Drawing Figures PATENTEDHAY 2 I972 3.660214 sum 1 OF 3 PRES/2E /5t.5TEP- BLOCK PREHEHT 5400/4 APPLY BOND/N6- 5rd$rEP- COAT T0 BLOI APPLY MATRIX 401 5TEP- T0 BOND/N6 COAT APPLY SLAB 51/; STEP-r MATERIAL T0 MA TR/X BY PRESSURE HPPLYS/IND OVER 6M STEP SLAB MTERML AND J OINTS HEAT BLOCK 7th STEP- /N cum/v OVEN Removs EXCESS th STEP" m INVENTORS CHARLES E M61404 5', JR.

GERALD Z How/1R0 PATENTEDMAY 2 1972 SHEET 30F 3 INVENTOPS CHARLES E NICHOLS, J/P.

GERALD T HOW/1RD BY 1 g WA TTOPNE Y5 j block. I v 2. Description of the'Prior Art I Heretofore, building blocks and the like intended to have a l. Field ofthe lnvention The present invention relates to a concrete wall panel, or the like having facing elements applied thereto to simulate a mortar-laid brick wall or to present. any other I desiredappearance. The invention further relates to a method and materials for applying the facing elements to the building surface simulating a brick wall have been made by securing facing slabs of brick to a concrete block by using mortar (Du- I la, ULS, Pat .No.'l,,41 1,005), or fby cementing" brick or tile to the concrete block (Willson, U.S. Pat. No. 1,844,828). Such blocks are subject to the objection that the slabs are not permanently adhered to the blocks and can be knocked off in 2 varyfrom'lessthan KinchtoZinch'esormore. Aslabthreeeighths inch thick is preferred for most applications. Alternatively, the slabs may be extruded ordry pressed, or extruded building block,

and wire cut, and then burned to provide slabs of the desired thickness rather than cut from whole brick witha ceramic saw. A'group. of slabs arranged'in predetermined pattern is held stationary by a auction head. Any given pattern can be matrix is of such body or consistency that when the block is raised by a cylinder, the matrix is pressed against the facing to partially and uniformly embed the slabs in the matrix, so that the slabs are retained in place and will not "drift relative to handling, or fall'offupon weathering of the mortar or cement.

There is the further objection that the facing slabs andthe material used'to secure them to the blocks do little, if

anything, to render the-outer face of the blockimpervious to moisture.

' SUMMARY or THEINVENTION The present invention avoids the objections noted above in that the facing rnaterialis not only permanently-secured to the block, or other building unit, but the bonding material used for the purpose renders the entire outer face of the block or unit impervious to moisture penetration. I

More specifically, the present invention relates to a concrete block or the like with facing material applied thereto simulating a mortar-laid construction, and to the method. and

polymerizable compositions used in making the same;

Conventional concrete and cinder building blocks are made ,in a moldwhich controls the width andlength of the block, but not height, which varies depending upon the 7 volume of the mix that is dnmped into the mold. As a result, the vertical height of the block is frequently greater than desired. in applying facing material to such blocks in accordance withthe present invention, it is important that the vertical height of the block conform to a predetermined dimension. This is necessary so that the facing material can be applied thereto in uniform size and uniformly spaced apart a distance equal to the thickness of a conventional mortar joint, and so that the resulting blocks, when laid to form a'brick wall, can be laid with the same conventional thickness of mortar joint therebetween. Consequently, the first step in the present process is to make certain that the block to be faced is of the desired vertical height. Ifthe height of the block is in excess of I that desired a portion of the upper side thereof is removed by a grinding wheel. The thus presized block is laid on its side and heat is applied to at least its upper surface to preheat the same to condition it for receiving and facilitating curing of a resinous bonding material. Such heating may take place'in a preheat oven and be effected by radiant, gas, electrical, or any suitable form of heat. After the top surface of the block is heated to a temperature of about 225 F., it is coated with a mixture containing a polyester resin, a styrene .monomer, a solvent, and a catalyst. After the solvent has been flashed off by the heat contained in the block, the bonding coat quickly pplymerizes. A'layer of matrix material of a thickness of about one-eighth inch is applied to the bonding coat over the entire top surface of the block. The matrix comprises a polyester resin, styrene monomer, silica flour and coloidal silica (Carbosil), and a catalyst.

Facing material, which may be in the form of brick slabs, marble, or other material, is then partially embedded in the matrix. Brick or marble facings can readily be provided by slicingbricks or pieces of marble into slabs with a ceramic saw. The slabs can be of any suitable thickness, which may s I 1 block or wall panel having facing material attached thereto to the block. While a polyester resin is the preferred method of applying the, slabs to the block faces, such thermosetting resins as epoxy resins, epoxy-novolacs, polyurethanes both ofv the polyester and polyester type can also-be used to attachthe slabs to the face of the block. Also,-thennoplastic resins such as acrylonitrile-butadiene-styrene resins, polyamides, vinyl compounds, acrylics and other thermoplastics may be used to attach the brick slabs to the block faces using heat. Fillers such as silica or calcium carbonate can be used withv all systems. r I

After the facing has been applied to the matrix, the block is lowered, and carried by the conveyer to a position where the entire block is covered with a thin layer of sand. it is then passed through a curing oven, or allowedto cure at room temperature, to polymerize the matrix and fuse it with the bonding coat and adhere the facing to the block. The particles of sand include this step because the sand adheres permanentlyto the matrix and truly simulatesa mortar joint, which is a valuable feature. When slabs of brick are used as a facing, the finished block simulates a portion of a brick wall having mortar joints. The step of preheating the block to cure the bonding coat, and

the step of heating the matrix to cure'it can be omitted, depending upon the amountof catalyst employed and upon whether slower curing at ambient temperature is acceptable.

The principal object of the invention is to provide a building simulate a brick wall or other structure, and to provide a simple and inexpensive method of the same.

Another object is to provide a masonry building unit that is competitive in price with other building materials, such as wood and metal. Y

Still another object is to provide building units simulating brick structures and embodying patterns not readily attainable with conventional brick at low labor cost. v

A further object is to provide a building unit simulating a brickstructure that will speed up construction and reduce the 1 amount of on site labor. 7

Another object is to provide simulated brick building units which are resistant to heat and cold and are impervious to the penetration of moisture. I

A still further object is to provide building units simulating brick structures that are easy to repair'and to replace in the event of damage.

Another object is to provide a building unit of any desired size with simulated brick or other facing elements arranged in any desired pattern, including reproductions of modern or antique patterns.

Other objects and advantages will be apparent from the following description and accompanying drawings.

usedincarryingoutonemethodofmakingafacedbuilding block; I

FIG. 2 diagrammatically illustrates the first step in the process, wherein the block is presized as to vertical height by grinding off excess material; I

FIG. 3 shows a brick partially cut into slabs to provide facing elements for the block;

FIG. 4 is a diagrammatic view of apparatus that can be used in carrying out one method of making the faced block;

FIG. 5 schematically illustrates the step of spraying the liquid bonding material on the upper side of the block;

FIG. 6 diagrammatically shows a nozzle applying a layer of the matrix mix over the bonding material;

FIG. 7 illustrates the block after the bonding material and matrix mix have been applied to it;

FIG. 8 diagrammatically illustrates a suction head carrying brick slabs, the block with matrix applied, the conveyor, and

cylinder for raising the block to press the matrix against the brick slabs;

FIG. 9 is a view similar to FIG. 8, but shows the block in its fully raised position;

FIG. 10 illustrates a hopper for dribbling sand over the top of the faced block;

FIG. 11 is a front elevational view of a block having one design arrangement of slab facings;

FIG. 12 is a horizontal sectional view, taken on the line 12 l2 ofFIG.1l;

FIG. 13 is an elevational view of a wall section constructed from blocks having another design of facing elements attached thereto simulating mortar-laid components;

FIG. 14 is a horizontal sectional view, taken on the line 14 14 of FIG. 13;

FIG. 15 is an elevational view of a third design of brickfaced block;

FIG. 16 is a horizontal sectional view, taken on the line 16 16 ofFlG. 15;

FIG. 17 is an elevational view of a faced block showing a conventional arrangement of brick slabs;

FIG. 18 is a horizontal sectional view, taken on the line 18 18 ofFlG. l7; and

FIG. 19 is a sectional view through another modification wherein facing elements are applied to a matrix backed by fiber glass cloth.

DESCRIPTION OF THE PREFERRED EMBODIMENTS As is well known, in the machine-manufacture of conventional cement and cinder blocks, it is desired that a predetermined volume of the cement mix be dumped into each mold. However, it is extremely difiicult to maintain the volume constant for each block, with the result that the blocks are of uniform length and width, but are not of uniform height. Therefore, for the purposes of the present invention, the first step is to presize the block. Thus, FIG. 2 illustrates a support 2 having angle irons 4, or any other suitable abutments, secured thereto for holding a conventional cement or cinder block 6 in a fixed position. A grinding wheel 8 is positioned a predetermined height above the support 2 so that as the support 2 is moved relative to the grinding wheel 8, or vice versa, the grinding wheel will quickly remove any excess material 10 above the prescribed vertical height of the block, which is indicated by the dimension X.

Referring to FIG. 4, the presized block 6 is turned over on its side and delivered to an endless conveyor 12 comprising pulleys or rolls l4 rotatably mounted upon shafts 16 at the opposite ends of the apparatus. The conveyer 12 is continuously driven, by means not shown, so that all operations occur in timed relation to the movement of the conveyer.

To effect the second or preheating step in the process, the conveyer 12.moves the presized block 6 into a preheating oven 18 that can be heated by any suitable means, for example, infrared lamps 20. The preheating is not intended to saturate the entire block 6 with heat, but rather to heat the upper surface 22 of each block as it passes through the preheating oven 18 to prepare it to receive a bonding material.

The conveyer l2 successively carries the preheated blocks 6 to a spray booth 24 whose interior is connected with a ventilating system through a duct 26, where the third step in the process is effected. A pipe 28 extends into the booth 24 and has a spray head 30 connected to one end thereof. The other end of the pipe 28 is connected to a source of liquid bonding material, which will be described in greater detail hereinafter. The spray head 30 applies a coating of bonding material 32, FIGS. 4 and 5, to the upper face 22 of the block as it is moved through the booth 24. The bonding material 32 penetrates the pores of the block 6 and aids in bonding the relatively lower viscosity matrix to the block, as will appear later. In view of the fact that the upper face 22 has been preheated, the solvent flashes off and the bonding coat 32 is polymerized in a short period of time. While a spray head 30 has been shown for applying the bonding coat to the block 6, it is to be understood that the coating may be applied by a brush or a roller, since only a coating sufficient to wet the surface of the block is necessary.

The conveyor 12 carries the block 6, with the polymerized coating of bonding material 32 thereon, to a position wherein the fourth step in the process is accomplished, i.e., a layer of matrix material 34 is deposited on the bonding coat 32.

Referring to FIG. 6, a relatively flat nozzle 36 is positioned to deposit a layer of the matrix material 34 on the bonding coat 32 as the block 6 is moved by the conveyor 12 past the nozzle 36. It is to be understood that the nozzle 36 has an elongated discharge opening that is approximately equal' to the width of the upper face 22 of the block 6, so that the entire upper surface of the block is covered by a layer of the matrix material 34. A valve 38 connected with the nozzle 36 is operated in time relation to the movement of the conveyor 12 so that the valve 38 opens as a block 6 is moved into position beneath the nozzle 36, and is closed after the full length of the block has been coated. The matrix 34 is supplied to the nozzle 36 through a pipe 40, FIG. 4, connected with the outlet of a pump 42. The inlet of the pump 42 is connected by a pipe 44 with a tank 46 containing a supply of the matrix 34. The matrix 34 is of a relatively thick consistency and remains in a plastic state until it has been polymerized.

The next, or fifth step in the process is to apply a slab or facing elements 47 to the matrix 34 by pressure. Accordingly, a suction head 48, FIGS. 4 and 8, is positioned above the path of the block 6 and is transferred from a loading position, into the stated position, from an area in which slabs of brick or other facings are arranged in predetermined relation in a jig (not shown). The slabs 47 may be arranged in groups of six in any one of the patterns shown in FIGS. ll, l3, 15, or 17. Such slabs or facings 47 are picked up by the head 48 under suction applied thereto through a pipe 50. Directly below the suction head 48 is a conventional cylinder 52 having a piston rod assembly 54 to the upper end of which a U-shaped platform 56 is attached. Operating fluid is supplied to and exhausted from the cylinder 52 through pipes A and B, as needed. The legs 57 of the platform 56 are movable through suitable openings in the conveyer 12 so that they can engage the lower face of the block 6 and move it upwardly from the position shown in FIG. 8 to the position shown in FIG. 9. Such movement of the block 6 presses the matrix 34 against the slabs 47 to partially embed the slabs to a uniform depth in the matrix. During this operation, a portion of the matrix 34 is forced into the space between the slabs 47, as indicated at 58 in FIG. 9 to simulate a mortar joint between the slabs. Suction to the head 48 is then relieved, as is also the pressure in the cylinder 52, so that the block 6 is lowered back onto the conveyer 12. The suction head 48 is then transferred to the loading position, previously referred to, to pick up the next group of pre-arranged slabs to be applied as facing to the next block 6.

The foregoing operations occur rapidly and in timed relation to the movement of the conveyer 12, so that the suction head 48 is always in proper position above a block 6 when operating fluid is admitted into the cylinder 52 through pipe B to raise the platform 56.

After the slab material 47 has been partially embedded in the matrix 34, and the platform 56 has been lowered, repositioning the block on the conveyer 12, the conveyer moves the block 6 to a position under a hopper 59 loaded with sand, to effect the sixth step in the process. The hopper 59 converges toward its lower end to form a narrow opening 60, FIG. 10, approximately equal to the width of the block 6. A gate 62 is pivoted at 64 on the hopper and is movable in timed relation to the movement of the conveyer (by means not shown) to open or close the opening 60. As a faced block 6 is moved into position below the opening 60, the gate 62 is opened and sand 66 is allowed to dribble onto the faced block. It will be understood that the sand covers the slabs 47 and enters the spaces between the slabs and directly contacts the matrix at the simulated joints between the slabs to form a sand overlay. The overlay covers the underlying matrix 34, which would not have the true appearance of a mortar joint and also protects it from damaging exposure to the sun and atmosphere.

The next or seventh step in the process is effected by the conveyer 12 moving the sanded" block 6 into a curing oven 68 wherein the temperature is about 250 F. in order to efiect a rapid curing or setting or polymerization of the matrix 34. After curing, the block 6 is carried by the conveyer 12 for discharge onto a support 70 from which it is removed and allowed to cool.

The eighth step takes place after cooling, when the block 6 is manually moved into a vertical position, or turned upside down so that the excess sand 66 falls from the block. The sand 66 does not adhere to the facing slabs 47, but does adhere to the exposed matrix between the slabs to present the appearance of a mortar joint. The sand 66 removed from the blocks 6 can be reclaimed and reused.

Thus, all of the steps depicted in FIG. 1 are accomplished, according to a preferred method.

FIG. 11 is an elevational view of a finished block 6, wherein slabs of brick or other suitable material 47 are arranged parallel in two groups of three slabs. The protruding matrix material 58, to which sand is adhered, simulates mortar joints so that the block presents the appearance of six bricks secured together by mortar. It will be noted that the upper and lowermost slabs 47 each have a longitudinal edge that coincides with the adjacent longitudinal edge of the block 6; and, further, that each of the slabs 47 has a transverse edge that coincides with the adjacent transverse edge of the block. The width of the joint space or between the slabs 47 corresponds to that conventionally used in laying brick, say, about threeeighths inch; wherefore, the finished block presents the appearance of six bricks held together by mortar. In order to attain the desired uniform spacing of the slabs 47 on all blocks so that uniformity is present in a wall built with the blocks, each block is presized to the vertical height X shown in FIG. 2. The dimension X is equal to the combined thickness of three bricks and two mortar joints. The brick arrangement if duplicated by hand-laid individual bricks, would be far more costly and require much more time than by building a wall using the faced block shown in FIG. 11.

FIG. 13 illustrates a modified design in which three slabs 47 of suitable size are arranged horizontally and three slabs 47a are arranged vertically on a block 6a. A group of blocks 60 is shown laid with staggered vertical mortar joints 72 and horizontal mortar joints 74 to provide a wall section simulating mortar-laid components. The pattern presented is nonconventional and would be expensive and time consuming if attempted to be duplicated by hand-laid, individual bricks.

FIG. 15 illustrates a third design arrangement of facing slabs, wherein all of the slabs 47b are arranged vertical and parallel. Here again, a hand-laid brick duplication would be costly and take a lot of time.

FIGS. 17 and 18 illustrate a fourth pattern design with facing elements 47c simulating a conventional brick wall pattern.

FIG. 19 diagrammatically illustrates a rectangular mold 76 comprising a bottom wall 78 and side walls 80. The mold 76 may be of any desired size and configuration and may be large enough to provide a panel for an entire room wall, or a decorative panel for the exterior of a building. In making a panel utilizing the mold 76, a sheet of woven fiber glass 82 is used as a backing, instead of a block. The fiber glass 82 is laid on the bottom wall 78. A layer of matrix 34a is then applied to the fiber glass sheet 82. The matrix 34 a may be of any desired thickness, but preferably is not less than three-eighths inch thick. Slabs of facing material 47d are partially embedded in the matrix material 34a in any desired pattern. A layer of sand is then applied over the facing material and the spaces therebetween and the matrix 34a is then allowed to cure. After curing, the structure is removed from the mold 76 and excess sand is removed. As in the previous structures, the sand adhering to the matrix 34a will simulate a mortar joint, and if brick slabs are used, the resulting panel will simulate a large brick wall section.

An interesting and unusual effect is obtained in the ultimate block if slabs of different thickness are adhered to the block (or other backing member). In such case, it will be apparent that some of the slabs will protrude farther from the face of the block than the remaining slabs.

The bonding material 32 and 32a comprises essentially a polyester resin, a polymerizable monomer, a catalyst, and a solvent. The matrix 34 and 344 comprises essentially the same polyester resin and polymerizable monomer as in the boning material, plus a catalyst and finely divided silica material.

As is well known, a polyester is formed from the condensation reaction of dicarboxylic acids with glycols to form esters. In preparing polyester suitable for use in the following specific examples, dicarboxylic acids, such as, malic anhydride, furmaric anhydride, phthalic anhydride, and isophthalic anhydride may be used singly, or in any combination, with glycols, such as ethylene glycol, dipropylene glycol, propylene glycol, diethylene glycol, bisphoneol A adduct, neopental glycol or trimethyl pentanediol either singly or in combination to form the ester portion of the polyester resin. The ester portion is preferably 60 percent but can vary between 10 to 95 percent of the resin formulation.

The polymerizable monomer in the following examples may be any one of, or a combination of two or more of the following monomers: styrene, dialyl phthalate, methyl methacrylate, vinyl toluene, triallyl cyanurate or chlorostyrene.

The catalyst used in the following examples may be one or more of a number of organic peroxides such as methyl ethyl ketone peroxide, benzoyl peroxide, di-tertiary butyl peroxide, cumene hydroperoxide, di-peroxesters, dialkyl peroxide, or aliphatic diacyl peroxide. These catalysts may be used with various promoters, such as, a cobalt soap of naphthenic acid, a cobalt soap of 2 ethylhexoic acid (Octoic Acid) and or various amines such as 2, 2, dimethyl amine or N, N dimethyl amine. Methyl-ethyl ketone peroxide, for example, is used when a low temperature and slow polymerization is desired; and di-tertiary butyl peroxide, for example, is used when a high temperature and relatively rapid polymerization is desired. There are various types of ketones that may be used such as methyl ethyl ketone, acetone, methyl isobutyl ketone, methyl iso-amyl ketone, etc..

EXAMPLE I Polyester resin 8 to percent, and preferably 10 percent Polymerizable monomer 7 to 90 percent, and preferably 8 percent Solvent (for example, acetone) 5 to 99.1 percent of total formulation and, preferably 82 percent Catalyst (for example, di-tertiary butyl peroxide) 0.1 to

10 percent, and preferably 1 percent based on the combined weight of the resin and monomer The bonding coat or adhesive 32 penetrates into the block 6 to increase the adhesive properties of the matrix layer 34 to be applied to the block. After the acetone flashes off, the bonding material will polymerize in about 5 minutes.

A layer of matrix material 34, about one-eighth inch thick,

is applied to the block 6 over the entire area of the bonding coat 32. The matrix is composed of the following materials in percentage by weight:

Polyester resin 8 to 90 percent, and preferably 12 percent Polymerizable monomer 6 to 90 percent, and preferably 8 percent Silica flour to 95 percent, and preferably 80 percent Coloidal silica O to 15 percent, and preferably 2 percent based on the weight of the resin Catalyst (for example, di-tertiary butyl peroxide) 0.1 to 10 percent, and preferably 1 percent, based on the weight of the resin Brick slabs or other material 47 are partially embedded in the matrix 34 in predetermined repetitive patterns, and sand 66 is applied to the entire area of the block 6 covering the slabs and the joints between the slabs. The sanded block is then heated in a curing oven 68 to a temperature of about 212 to 350 F. and preferably about 250 F. for a period of about 25 minutes. Such heating will polymerize the matrix 34 and permanetly bond the facing material 47 to the block 6.

EXAMPLE II The bonding material 32 may be applied to a block 6 at a lower temperature than that prescribed in Example I, that is, at a block temperature of about 15 to 225 F.. In such instance, the bonding coat may have the following composition:

Polyester resin 8 to 90 percent, and preferably 10 percent Polymerizable monomer 6 to 90 percent, and preferably 8 percent Catalyst (for example, methyl ethyl ketone peroxide) 0.1 to 10 percent, and preferably 1 percent based on the weight of the resin Solvent (for example, acetone) to 99.9 percent and preferably 81 percent, based on the weight of the total formulation After the acetone evaporates, polymerization is effected in about 5 minutes. In this example, the matrix 34 may have the following composition in percentage by weight:

Polyester resin 8 to 90 percent, and preferably 12 percent Polymerizable monomer 6 to 90 percent, and preferably 8 percent Silica flour 0 to 95 percent, and preferably 80 percent Coloidal silica 0 to 15 percent, and preferably 2 percent Catalyst (for example, methyl ethyl ketone peroxide) 1 to percent, and preferably 1 percent; the percentage weight of the coloidal silica and methyl ethyl ketone peroxide being respectively based on the weight of the resin and monomer The matrix 34 is applied over the bonding coat 32 in a layer about one-eighth inch thick. Brick slabs or other facing 47 is partially embedded in the matrix and sand is applied over the entire top face of the block. The step of oven curing can be eliminated by allowing polymerization to take effect at room temperature, which will require about 24 hours.

The period of time required for polymerization depends on the temperature and catalyst concentration. The catalyst concentration can be as low as 0.25 percent or as high as 10 percent, based on the weight of the resin. The polymerization time can be as little as 30 seconds or as long as 24 hours. As a general rule, polymerization time is shortened with increased temperature or type of catalyst and percentage, or type of promoter and percentage thereof.

One convenient way of forming the facing slabs is to take an ordinary brick and slice it (FIG. 3) with a ceramic saw to provide slabs 47 about 7% 2% inch thick. The size of the slabs may vary depending upon the final pattern desired on the block. The brick slab material may vary in thickness from V4 to 2 inches with a preferred thickness of three-eighths inch.

In all forms of the invention, the bonding coat 32 is homogeneously united with the matrix 34 and they jointly provide a vapor barrier at the outer surface of the block, which renders it impervious to moisture. The adhesive material i.e., the bonding coat 32 and matrix 34) is stronger than the block material and renders the block resistant to impact.

Faced blocks constructed in accordance with the present method have been subjected to freeze and thaw tests of 1,000 cycles in a standard laboratory testing machine, the temperatures ranging from as low as 250 to --70 F. and to as high as 120 F., without any problem resulting from the repeated thermal expansion and contraction of the blocks, adhesive, and facing material. The coefficient of thermal expansion of the bonding coat and matrix is 1.31 X 10" unit unit F. at 100 F..

It will be understood that various changes may be made in the examples given herein and in the methods described without departing from the principles of the invention.

We claim:

1. A structural building unit for use in constructing a wall simulating mortar-laid components, comprising: a backing member in the form of a conventional masonry building block having on one face thereof a bonding coat comprising curable resinous material; a layer of matrix comprising a curable resinous material adhered to the bonding material; a plurality of pieces of slab facing material arranged in a predetermined repetitive pattern on said one face of said block, said pieces of slab facing material being about V4 to 2 inches in thickness and being partially and uniformly embedded in the matrix and being spaced apart a distance equal to the width of a conventional mortar joint with the non-embedded portions of said pieces of slab facing material exposed to the atmosphere; and a sand overlay simulating a mortar joint adhered to the matrix in the spaces between the pieces of slab of facing material.

2. A structural building unit as defined in claim 1, in which the backing member is a building block, presized to provide a side thereon of a predetermined width, and wherein the bonding coat, matrix, and facing pieces are applied to said side.

3. A structural building unit as defined in claim 1, in which the bonding coat and matrix each comprise a polyester resin and a polymerizable monomer.

4. A structural building unit as defined in claim 1, in which the bonding coat comprises, by weight:

polyester resin 8 to percent;

polymerizable monomer 7 to 90 percent;

solvent 5 to 99.1 percent by weight of the resin and monomer; and

catalyst 0.1 to 10 percent, by weight of the resin.

5. A structural building unit as defined in claim 1, in which the layer of matrix comprise;

polyester resin 8 to 90 percent;

polymerizable monomer 6 to 90 percent;

silica flour 0 to percent;

coloidal silica 0 to 15 percent, by weight of the resin", and

catalyst l to 10 percent, by weight of the resin.

6. A structural building unit as defined in claim 13, in which the matrix comprises:

polyester resin 8 to 90 percent;

polymerizable monomer 6 to 90 percent;

silica flour 0 to 95 percent;

coloidal silica 0 to 15 percent, by weight of the resin and monomer; and

catalyst about 0.1 to 10 percent, by weight of the resin and monomer.

7. A structural building unit as defined in claim 1, in which the bonding coat comprises, by weight:

polyester resin about 10 percent;

polymerizable monomer about 8 percent;

solvent about 82 percent; and

catalyst about 1 percent by weight of the resin and monomer.

8. A structural building unit as defined in claim 7, in which the monomer is styrene, the solvent is acetone, and the catalyst is di-tertiary butyl peroxide.

9. A structural building unit as defined in claim 1, in which the layer of matrix comprises, by weight:

polyester resin about 12 percent;

polymerizable monomer about 8 percent;

silica flour about 8 percent;

coloidal silica about 2 percent, by weight of the resin; and

catalyst about 1 percent, by weight of the resin.

10. A structural building unit as defined in claim 9, in which the monomer is styrene, and the catalyst is di-tertiary butyl peroxide.

11. A structural building unit as defined in claim 1, in which the matrix comprises, by weight:

polyester resin about 12 percent;

polymerizable monomer about 8 percent;

silica flour about 80 percent;

coloidal silica about 2 percent, by weight of the resin and monomer; and

catalyst about 1 percent, by weight of the resin and monomer.

12. A structural building unit as defined in claim 11, in which the monomer is styrene and the catalyst is methyl-ethyl ketone peroxide.

13. A structural building unit as defined in claim 1, in which the bonding coat comprises:

polyester resin 8 to 90 percent;

polymerizable monomer 6 to 90 percent;

catalyst 0.1 to 10 percent, by weight of the resin; and

solvent to 99.9 percent, by weight of the resin and monomer.

14. A structural building unit as defined in claim 13, in which the bonding coat comprises, by weight:

polyester resin about percent;

polymerizable monomer about 8 percent;

solvent about 81 percent; and

catalyst about 1 percent.

15. A structural building unit as defined in claim 14, in which the monomer is styrene, the catalyst is methyl ethyl ketone peroxide; and the solvent is acetone.

16. A structural building unit for use in constructing a wall simulating mortar-laid components comprising: a backing member in the form of a conventional masonry building block having on one face thereof a bonding coat comprising a thermoplastic or thermosetting resinous material; a layer of matrix comprising a thermoplastic or thermosetting resinous material adhered to the bonding material; a plurality of pieces of slab facing material arranged in a predetermined repetitive pattern on said one face of said block, said pieces of slab facing material being about A to 2 inches in thickness and being partially and uniformly embedded in the matrix and being spaced apart a distance equal to the width of a conventional mortar joint with the non-embedded portions of said pieces of facing material exposed to the atmosphere; and a sand overlay simulating a mortar joint adhered to the matrix in the spaces between the slabs of facing material.

17. A structural building unit as recited in claim 16, in which the thermoplastic or thermosetting resinous material of the bonding coat is selected from the group consisting of epoxy-novolacs, polyurethanes both of the polyester and polyether type, acrylonitrile-butadiene-styrene resins, polyamides, vinyl compounds, acrylics, and epoxy resins.

18. A structural building unit as recited in claim 16, in which the thermoplastic or thermosetting resinous material of the matrix is selected from the group consisting of epoxynovolacs, polyurethanes both of the polyester and polyether type, acrylonitrile-butadiene-styrene resins, polymides, vinyl compounds, and acrylics; and wherein the matrix includes a filler.

19. A self-sustaining structural building unit for use in constructing a wall simulating mortar-laid components comprising: a backing member in the form of a conventional masonry building block having on one face thereof a layer of matrix comprising a curable resinous material; a plurality of pieces of slab facing material arranged in a predetermined repetitive pattern on said one face of said block, said pieces of slab fac-- ing material being about V4 to 2 inches in thickness and being partially embedded in the matrix to a uniform depth with the non-embedded portions thereof exposed to the atmosphere, said pieces of slab facing material being spaced apart a distance equal to the width of a conventional mortar joint; and a sand overlay simulating a mortar joint adhered to the matrix in the spaces between the pieces of slab facing material.

20. A structural building unit as defined in claim 19 wherein each of the slabs has at least one edge thereof coinciding with an edge of the block.

21. A structural building unit a defined in claim 19, in which the matrix is a thermosetting epoxy resin.

22. A structural building unit as defined in claim 19, in which the layer of matrix comprises:

polyester resin 8 to percent;

polymerizable monomer 6 to 90 percent;

silica flour 0 to percent;

coloidal silica 0 to 15 percent, by weight of the resin; and

catalyst l to 10 percent, by weight of the resin.

23. A structural building unit as defined in claim 19, in which the layer of matrix comprises, by weight:

polyester resin about 12 percent;

polymerizable monomer about 8 percent;

silica flour about 8 percent;

coloidal silica about 2 percent, by weight of the resin; and

catalyst about 1 percent, by weight of the resin.

24. A structural building unit as defined in claim 19, in which the matrix comprises:

polyester resin 8 to 90 percent;

polymerizable monomer 6 to 90 percent;

silica flour 0 to 95 percent;

coloidal silica 0 to 15 percent, by weight of the resin and monomer; and

catalyst about 0.1 to 10 percent, by weight of the resin and monomer.

25. A structural building unit as defined in claim 19, in which the matrix comprises, by weight:

polyester resin about 12 percent;

polymerizable monomer about 8 percent;

silica flour about 80 percent;

coloidal silica about 2 percent, by weight of the resin and monomer; and

catalyst about 1 percent, by weight of the resin and monomer.

26. A structural building unit as defined in claim 19, in which the matrix comprises a polyester resin and a polymerizable monomer.

27. A structural building unit as defined in claim 26, in which the polyester resin is selected from the group consisting of the reaction product of a dicarboxylic acid selected from the group comprising malic anhydride, furmaric anhydride, phthalic anhydride, and isophthalic anhydride used singly or in any combination with one or more glycols, selected from the group comprising ethylene glycol, dipropylene, glycol, propylene glycol, diethylene glycol, bisphoneol A adduct, neopental glycol or trimethyl pentanedoil ether.

28. A structural building unit as defined in claim 26, in which the polymerizable monomer is selected from the group consisting of styrene, dialyl phthalate, methyl methacrylate, vinyl toluene, triallyl cyanurate or chlorostyrene.

29. A structural building unit as defined in claim 26, in which the bonding coat includes a catalyst selected from the group consisting of ethyl ketone peroxide, benzoyl peroxide, di-tertiary butyl peroxide, cumene hydroperoxide, di-peroxesters, dialkyl peroxide, or aliphatic diacyl peroxide.

i U l I I 

2. A structural building unit as defined in claim 1, in which the backing member is a building block, presized to provide a side thereon of a predetermined width, and wherein the bonding coat, matrix, and facing pieces are applied to said side.
 3. A structural building unit as defined in claim 1, in which the bonding coat and matrix each comprise a polyester resin and a polymerizable monomer.
 4. A structural building unit as defined in claim 1, in which the bonding coat comprises, by weight: polyester resin 8 to 90 percent; polymerizable monomer 7 to 90 percent; solvent 5 to 99.1 percent by weight of the resin and monomer; and catalyst 0.1 to 10 percent, by weight of the resin.
 5. A structural building unit as defined in claim 1, in which the layer of matrix comprise: polyester resin 8 to 90 percent; polymerizable monomer 6 to 90 percent; silica flour 0 to 95 percent; coloidal silica 0 to 15 percent, by weight of the resin; and catalyst 1 to 10 percent, by weight of the resin.
 6. A structural building unit as defined in claim 13, in which the matrix comprises: polyester resin 8 to 90 percent; polymerizable monomer 6 to 90 percent; silica flour 0 to 95 percent; coloidal silica 0 to 15 percent, by weight of the resin and monomer; and catalyst about 0.1 to 10 percent, by weight of the resin and monomer.
 7. A structural building unit as defined in claim 1, in which the bonding coat comprises, by weight: polyester resin about 10 percent; polymerizable monomer about 8 percent; solvent about 82 percent; and catalyst about 1 percent by weight of the resin and monomer.
 8. A structural building unit as defined in claim 7, in which the monomer is styrene, the solvent is acetone, and the catalyst is di-tertiary butyl peroxide.
 9. A structural building unit as defined in claim 1, in which the layer of matrix comprises, by weighT: polyester resin about 12 percent; polymerizable monomer about 8 percent; silica flour about 8 percent; coloidal silica about 2 percent, by weight of the resin; and catalyst about 1 percent, by weight of the resin.
 10. A structural building unit as defined in claim 9, in which the monomer is styrene, and the catalyst is di-tertiary butyl peroxide.
 11. A structural building unit as defined in claim 1, in which the matrix comprises, by weight: polyester resin about 12 percent; polymerizable monomer about 8 percent; silica flour about 80 percent; coloidal silica about 2 percent, by weight of the resin and monomer; and catalyst about 1 percent, by weight of the resin and monomer.
 12. A structural building unit as defined in claim 11, in which the monomer is styrene and the catalyst is methyl-ethyl ketone peroxide.
 13. A structural building unit as defined in claim 1, in which the bonding coat comprises: polyester resin 8 to 90 percent; polymerizable monomer 6 to 90 percent; catalyst 0.1 to 10 percent, by weight of the resin; and solvent 5 to 99.9 percent, by weight of the resin and monomer.
 14. A structural building unit as defined in claim 13, in which the bonding coat comprises, by weight: polyester resin about 10 percent; polymerizable monomer about 8 percent; solvent about 81 percent; and catalyst about 1 percent.
 15. A structural building unit as defined in claim 14, in which the monomer is styrene, the catalyst is methyl ethyl ketone peroxide; and the solvent is acetone.
 16. A structural building unit for use in constructing a wall simulating mortar-laid components comprising: a backing member in the form of a conventional masonry building block having on one face thereof a bonding coat comprising a thermoplastic or thermosetting resinous material; a layer of matrix comprising a thermoplastic or thermosetting resinous material adhered to the bonding material; a plurality of pieces of slab facing material arranged in a predetermined repetitive pattern on said one face of said block, said pieces of slab facing material being about 1/4 to 2 inches in thickness and being partially and uniformly embedded in the matrix and being spaced apart a distance equal to the width of a conventional mortar joint with the non-embedded portions of said pieces of facing material exposed to the atmosphere; and a sand overlay simulating a mortar joint adhered to the matrix in the spaces between the slabs of facing material.
 17. A structural building unit as recited in claim 16, in which the thermoplastic or thermosetting resinous material of the bonding coat is selected from the group consisting of epoxy-novolacs, polyurethanes both of the polyester and polyether type, acrylonitrile-butadiene-styrene resins, polyamides, vinyl compounds, acrylics, and epoxy resins.
 18. A structural building unit as recited in claim 16, in which the thermoplastic or thermosetting resinous material of the matrix is selected from the group consisting of epoxy-novolacs, polyurethanes both of the polyester and polyether type, acrylonitrile-butadiene-styrene resins, polymides, vinyl compounds, and acrylics; and wherein the matrix includes a filler.
 19. A self-sustaining structural building unit for use in constructing a wall simulating mortar-laid components comprising: a backing member in the form of a conventional masonry building block having on one face thereof a layer of matrix comprising a curable resinous material; a plurality of pieces of slab facing material arranged in a predetermined repetitive pattern on said one face of said block, said pieces of slab facing material being about 1/4 to 2 inches in thickness and being partially embedded in the matrix to a uniform depth with the non-embedded portions thereof exposed to the atmosphere, saId pieces of slab facing material being spaced apart a distance equal to the width of a conventional mortar joint; and a sand overlay simulating a mortar joint adhered to the matrix in the spaces between the pieces of slab facing material.
 20. A structural building unit as defined in claim 19 wherein each of the slabs has at least one edge thereof coinciding with an edge of the block.
 21. A structural building unit a defined in claim 19, in which the matrix is a thermosetting epoxy resin.
 22. A structural building unit as defined in claim 19, in which the layer of matrix comprises: polyester resin 8 to 90 percent; polymerizable monomer 6 to 90 percent; silica flour 0 to 95 percent; coloidal silica 0 to 15 percent, by weight of the resin; and catalyst 1 to 10 percent, by weight of the resin.
 23. A structural building unit as defined in claim 19, in which the layer of matrix comprises, by weight: polyester resin about 12 percent; polymerizable monomer about 8 percent; silica flour about 8 percent; coloidal silica about 2 percent, by weight of the resin; and catalyst about 1 percent, by weight of the resin.
 24. A structural building unit as defined in claim 19, in which the matrix comprises: polyester resin 8 to 90 percent; polymerizable monomer 6 to 90 percent; silica flour 0 to 95 percent; coloidal silica 0 to 15 percent, by weight of the resin and monomer; and catalyst about 0.1 to 10 percent, by weight of the resin and monomer.
 25. A structural building unit as defined in claim 19, in which the matrix comprises, by weight: polyester resin about 12 percent; polymerizable monomer about 8 percent; silica flour about 80 percent; coloidal silica about 2 percent, by weight of the resin and monomer; and catalyst about 1 percent, by weight of the resin and monomer.
 26. A structural building unit as defined in claim 19, in which the matrix comprises a polyester resin and a polymerizable monomer.
 27. A structural building unit as defined in claim 26, in which the polyester resin is selected from the group consisting of the reaction product of a dicarboxylic acid selected from the group comprising malic anhydride, furmaric anhydride, phthalic anhydride, and isophthalic anhydride used singly or in any combination with one or more glycols, selected from the group comprising ethylene glycol, dipropylene, glycol, propylene glycol, diethylene glycol, bisphoneol A adduct, neopental glycol or trimethyl pentanedoil ether.
 28. A structural building unit as defined in claim 26, in which the polymerizable monomer is selected from the group consisting of styrene, dialyl phthalate, methyl methacrylate, vinyl toluene, triallyl cyanurate or chlorostyrene.
 29. A structural building unit as defined in claim 26, in which the bonding coat includes a catalyst selected from the group consisting of ethyl ketone peroxide, benzoyl peroxide, di-tertiary butyl peroxide, cumene hydroperoxide, di-peroxesters, dialkyl peroxide, or aliphatic diacyl peroxide. 